Control and Instrumentation for Steam Turbines in Power Plants

Turbines & Compressors Engineering Bharat Heavy Electricals Limited Hyderabad, India

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Automation: Requirement, concept & Solutions C&I play a major role in realising the following objectives of any power plant safety for plant and personnel increased plant availability

longer equipment life

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Automation: Requirement, concept & Solutions Safe and Reliable operation of Steam Turbines places heavy demands on the equipment used for Automation and for implementation of dependable and economical solutions.

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Automation: Requirement, concept & Solutions The Proven concept of Automation meets the tasks involved in following three levels. Regular Operation (Monitoring) Management of Disturbances (Control) Handling of Adverse events (Protection)
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Automation: Requirement, concept & Solutions

Regular Operation
Normal operation of the turbine is checked by supervisory devices such as analog controller, binary control elements and monitoring equipment.
E.g.:gland steam pressure controller, drive control interface for pumps, TSI etc.
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Automation: Requirement, concept & Solutions

Management of Disturbances
The limiting Devices detect deviations from normal operation and initiate counter measures to return the turbine to normal conditions
E.g.:Start-up of stand by pump on low lube oil pressure
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Automation: Requirement, concept & Solutions

Handling of Adverse conditions

Protective equipment shuts off the turbine or parts of the equipment in case of circumstances endangering persons or the turbine which cannot be maintained anymore within safe limits E.g.:Low lube oil pressure protection
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Automation: Requirement, concept & Solutions Measured value Threshold for response of protective device Threshold of limiting device Set point

time
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Automation: Requirement, concept & Solutions Modern Digital I&C equipment features a modular design. Accordingly a safe and economical configuration can be customised for any application , tailored to the rating of the turbine.

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Typical Configuration

Plant information network MAXSTATIONS ENGINEERS STATION

Redundant 100 Mbps MAXNET

MAXLINK

FIBRE OPTIC LINK REMOTE PROESSING UNITS PLANT SUB-SYSTEMS

REMOTE I/O

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Principle Modules of Automation

Turbine Interlocks and Protection

Turbine Stress Evaluator (TSE)

Seal Steam Control Turbine Supervisory Instrumentation (TSI) Electro Hydraulic Turbine Control (EHTC) Automatic Turbine Run-up System (ATRS)

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Turbine Protection: Purpose

To detect incipient irregularities and initiate the safety shutdown operations so as to minimise damage, repair costs and outages.

Last link in a chain of measures to designed to prevent or minimise the damage.

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Turbine Protection: categorization

Mandatory trips Optional trips Mechanical protections

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Turbine Protection
Description Lube oil pressure Very low HP steam temperature Very low Set Value < 1.0 Kg/sq.cm < 515 deg.c > 550 deg.c < 4.5 Kg/sq.cm(g)

HP steam temperature Very high

Control Oil Header Pressure Very Low Trip Oil Pressure Very Low Cond. pressure(vacuum) Very high Axial displacement Very high

< 2.0 Kg/sq.cm(g)

> -0.4 Kg/sq.cm(g) > +/- 0.7 mm

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Turbine Protection
Description Turbine Speed Very high Set Value > 3300 rpm

Tur. & Gen. Shaft Vibration V. High > 240 microns

Tur. & Gen. Brg. Temp. V. High

Emergency Trip Push Button H R S G Trip Operated Generator Trip Operated Trip from ATRS

> 115 Deg C Operated Operated

Operated
Operated

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Turbine Stress Evaluator The steam temperatures inside the turbine vary with change in operating conditions( start-up,loading, load change, shutdown).The resulting temperature differences give rise to material stresses. TSE provides the basis for operating with maximum permissible thermal stress.
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Turbine Stress Evaluator: Design The input parameters are the wall temperature sensors(thermocouples) measured at characteristic points of turbine like Admission Turbine shaft

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Turbine Stress Evaluator: Design

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Turbine Stress Evaluator: Design TSE Limit curves

DTallow

Tm

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Seal Steam Pressure Control

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Electro Hydraulic Turbine Control (EHTC) High flexibility High operational safety & reliability

Easy integration with TSE, ATRS.

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Electro Hydraulic Turbine Control (EHTC)

IP INJ. PR.CONTROL
SEL. LOGIC IP I/H CONV.

HP VLV. LIFT REF. SET.

SPEED CONTR M I N HP I/H CONV.

HP INLET PR.CONTROL

LP INJ. PR.CONTROL

SEL. LOGIC

LP I/H CONV.

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EHTC: Speed control loop Control speed during start-up and synchronisation Turbine stress margins limit the speed acceleration rate Speed acceleration monitoring

TSE temperature margin

Acceleration rate
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EHTC: HP pressure control loop

Sliding pressure mode Limit pressure mode

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EHTC: IP & LP Injection Pressure control loop IP injection pressure control maintains IP injection pressure LP injection pressure control maintains LP injection pressure

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TSI monitors Relative shaft vibration

Thrust position
3500 Monitoring System

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Automatic Turbine Runup System (ATRS) :Philosophy Subgroup Control (SGC) e.g.:Oil system,condensate &evacuation system and Turbine system Subloop Control (SLC)

e.g.:Lube oil pumps etc.

Control Interface(CI) e.g:main oil pump,jacking oil pump etc.
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Automatic Turbine Runup System (ATRS) :Philosophy

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Automatic Turbine Runup System (ATRS) :Philosophy SGC Executes commands to bring the equipment upto a particular state and contains the start-up and shutdown programme of the particular group. The programme comprises of different steps SGC issues commands to SLC/CI at each step Provision for monitoring time and waiting time at each step
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Automatic Turbine Runup System (ATRS) :Philosophy OPERATOR GUIDE MODE: In this mode data is received from plant but commands are not issued.Useful for commissioning and training. STEP MODE: In this mode programme is executed one step at a time.Useful when system criteria is met but cannot proceed because of switch/transmitter malfunctioning.
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Automatic Turbine Runup System (ATRS) :Philosophy CONTROL INTERFACE: It is the interface between SGC/SLC and MCC.It prioritises the commands from SGC/SLC and issues commands to MCC. SUB LOOP CONTROL:

It enables the process condition for automatic start-up of the drive.

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Automatic Turbine Runup System (ATRS) :SGC oil system

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ATRS :Oil system Operation

STEP 1: Starting Step. STEP 2: SLC Main oil pumps ON. STEP 3: Oil temperature control auto mode. STEP 4: SLC EOP on and SLC JOP 1 & 2 on.

STEP 5: Turning gear on.

STEP 6: checking for speed > 540 rpm.

STEP 7: checking for jacking oil pumps off.

STEP 8: check for turbine speed < 510 rpm. If not go to step-1.
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ATRS :Oil system shutdown

STEP 51: SLC Turning gear put off. STEP 52: check for turbine standstill.

STEP 53: waiting

STEP 54: SLC jacking oil pumps off.

STEP 55: SLC oil pumps off.

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ATRS :Cond&evac operation

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ATRS :cond&evac Operation

STEP 1: SLC CEP & GSCEF on. STEP 2: Check back for CEP & GSCEF on. STEP 3: Vacuum breaker valve close; Gland steam controller close/manual STEP 4: Vacuum pump1 & 2 on. STEP 5: Air inlet valve 1 & 2 on. STEP 6: Gland steam controller put on auto. STEP 7: check for cond.press < 0.1 kg/sq.cm(a) and load >5%.

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ATRS :cond&evac Operation

STEP 8: switch off unselected vacuum pump.
STEP 9: check for cond.press > 0.15 kg/sq.cm(a). If yes go to step 1 / if not go to step 10

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ATRS :cond & evac shutdown

STEP 51: switch off vacuum pump 1&2, air
inlet valves 1&2 close. STEP 52: Vacuum breaker valve open. STEP 53: Gland steam control close. STEP 54: SLC CEP and GSCEF off.

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ATRS :Turbine operation release criteria

position setpoint turbine controller<0% generator breaker off synchroniser off Vent before ESV not closed ESV closed

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ATRS :Turbine operation

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ATRS :turbine Operation

STEP 1: SLC drains on.
STEP 2: Check for cond. Pr, Trip Oil Pr & DT casing top/bottom. STEP 3: no command. STEP 4: Check for X1 & X2 criterion. STEP 5: HP ESV open. STEP 6: check for HP ESV open. STEP7: Check for X4 & X5 criterion.
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ATRS :turbine Operation

STEP 8: raise the speed SP to warm-up speed. STEP 9:check for actual speed reached for warm-up speed . STEP 10: check for X6 criterion. Check for TSE margin>30K STEP 11: no command. STEP 12: Raise Turbine speed to rated speed.

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ATRS : turbine Operation

STEP 13: Check for actual speed reached rated speed. STEP 14: AVR auto STEP 15: Waiting STEP 16: Synchroniser on. Check for generator breaker on. STEP 17: load to auxiliary load.

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ATRS :turbine shut-down

STEP 51: SLC drains on. STEP 52: HP, IP & LP control off. STEP 53: lower speed SP to 0% . STEP 54: actuate turbine trip channels synchroniser off generator field breaker open STEP 55: vent & drain before ESV open.

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ATRS :turbine Operation X1 criterion MS temp. before ESV Criterion fulfilled

HP ESV mid wall temp

DT (MS Temp. bef. ESV / HP ESV mid wall tem. > X1
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ATRS :turbine Operation X2 criterion MS sat.temp. before ESV Criterion fulfilled HP ESV mid wall temp
DT (MS sat. Temp. / HP ESV mid wall tem. < X2
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ATRS :turbine Operation X4 criterion MS temp. before ESV Criterion fulfilled

MS Sat. temp
DT (MS Temp. bef. ESV / MS sat. temp. > X4
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ATRS :turbine Operation X5 criterion MS temp. before ESV

Criterion fulfilled

HP shaft temperature
DT (MS Temp. bef. ESV / HP shaft temp. > X5
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ATRS :turbine Operation X7 criterion MS temp. before ESV Criterion fulfilled HP shaft temperature
DT (MS Temp. bef. ESV / HP shaft temp. < X7
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Conclusion BHEL is capable of providing complete control and instrumentation solutions which shall be Cost effective Of latest technology Meeting the customers specification requirements

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